JP6973970B2

JP6973970B2 - Core unit and reactor

Info

Publication number: JP6973970B2
Application number: JP2017080092A
Authority: JP
Inventors: 浩太郎鈴木; 勉 ▲濱▼田
Original assignee: Tamura Corp
Current assignee: Tamura Corp
Priority date: 2017-04-13
Filing date: 2017-04-13
Publication date: 2021-12-01
Anticipated expiration: 2037-04-13
Also published as: JP2018182082A

Description

本発明は、複数のコア部材が樹脂により一体化されたコアユニット及びリアクトルに関する。 The present invention relates to a core unit and a reactor in which a plurality of core members are integrated with a resin.

リアクトルは、ハイブリッド自動車や電気自動車の駆動システム等をはじめ、種々の用途で使用されている。例えば、車載用の昇圧回路に用いられるリアクトルとして、コアの周囲に配置した樹脂製のボビンにコイルを巻回したものが多く用いられる。 Reactors are used in a variety of applications, including drive systems for hybrid and electric vehicles. For example, as a reactor used in an in-vehicle booster circuit, a coil wound around a resin bobbin arranged around a core is often used.

この種のリアクトルとして、コアには、コイルなどの他の部材との絶縁を図るため、コアの周囲を被覆する樹脂部材が設けられる。この樹脂部材で被覆されたコアは、その一部にコイルが装着された状態で、ケースに収容される。 As this kind of reactor, the core is provided with a resin member that covers the periphery of the core in order to insulate the core from other members such as a coil. The core coated with this resin member is housed in a case with a coil mounted on a part thereof.

コアとしては、例えば、圧粉磁心が用いられる。圧粉磁心は、磁性粉末を含む磁性材料を金型に充填し、プレスして成形されることで形成される。具体的には、圧粉磁心は、圧粉磁心の形状をなす所定形状の貫通孔が設けられた柱状のダイスと、貫通孔の上側、下側から挿入し、貫通孔内に充填した磁性材料をプレスする上パンチ、下パンチを用いて製造される。貫通孔の形状をＵ字形状とすると、Ｕ字型コアを製造することができ、Ｅ字形状とするとＥ字型コアを製造することができる。 As the core, for example, a dust core is used. The dust core is formed by filling a mold with a magnetic material containing magnetic powder and pressing the mold. Specifically, the dust core is a columnar die provided with a through hole having a predetermined shape in the shape of the dust core, and a magnetic material inserted from above or below the through hole and filled in the through hole. Manufactured using an upper punch and a lower punch to press. If the shape of the through hole is U-shaped, a U-shaped core can be manufactured, and if it is E-shaped, an E-shaped core can be manufactured.

特開２０１３−０２６４２０号公報Japanese Unexamined Patent Publication No. 2013-026420

電気特性を満足するために、プレス方向の大きさを大きくする必要がある。磁性粉末を含む磁性材料を金型内に入れてプレスしてコアを成形する場合、成形したコアを金型内から取り出す際に、そのプレス方向にコアが大きいと、コア表面が金型内壁と摺動することによりキズが生じ、歩留まりが悪化する場合がある。そのため、プレス方向に大きいコアを成形できず、プレス方向の寸法に制約があった。 In order to satisfy the electrical characteristics, it is necessary to increase the size in the pressing direction. When a magnetic material containing magnetic powder is placed in a mold and pressed to form a core, when the molded core is taken out from the mold, if the core is large in the pressing direction, the core surface becomes the inner wall of the mold. Sliding may cause scratches and worsen the yield. Therefore, it is not possible to form a large core in the pressing direction, and there are restrictions on the dimensions in the pressing direction.

また、電気特性を満足するために、プレス方向の大きさを大きくする必要があるが、コアの大きさを大きくすることで、コア内部の熱が放熱できないという問題があった。 Further, in order to satisfy the electrical characteristics, it is necessary to increase the size in the pressing direction, but there is a problem that the heat inside the core cannot be dissipated by increasing the size of the core.

本発明は上記のような課題を解決するためになされたものであり、その目的は、コアのプレス方向の大きさの制約を受けず、コア内部の熱を放熱することのできるコアユニット及びリアクトルを提供することにある。 The present invention has been made to solve the above-mentioned problems, and an object thereof is a core unit and a reactor capable of dissipating heat inside the core without being restricted by the size of the core in the pressing direction. Is to provide.

本発明のコアユニットは、複数のコア部材がそのプレス方向に沿って隙間を空けて配列されてなる第１のコアと、前記複数のコア部材の周囲の少なくとも一部を被覆するとともに、当該複数のコア部材を固定して前記第１のコアを構成する第１の樹脂体と、を備え、前記隙間には、前記第１の樹脂体を構成する樹脂が前記複数のコア部材に密着して介在し、前記第１の樹脂体には、前記隙間の部分に前記樹脂の注入痕と、前記注入痕を介在させて対向し、前記コア部材のプレス方向と直交する直交面を露出させる一対の第１の開口部と、が設けられていること、を特徴とする。
The core unit of the present invention covers at least a part of the periphery of a first core in which a plurality of core members are arranged with a gap along the pressing direction, and the plurality of core members. A first resin body constituting the first core by fixing the core member of the above is provided, and the resin constituting the first resin body is in close contact with the plurality of core members in the gap. A pair of intervening and facing the first resin body with the injection mark of the resin interposed therebetween in the gap portion to expose an orthogonal surface orthogonal to the pressing direction of the core member. It is characterized in that a first opening is provided.

また、本発明のコアユニットは、複数のコア部材がそのプレス方向に沿って隙間を空けて配列されてなる第２のコアと、前記第２のコアを収容するケースと、前記複数のコア部材の周囲の少なくとも一部を被覆するとともに、当該複数のコア部材を固定して前記第２のコアを構成し、かつ、前記ケースと接合された第２の樹脂体と、を備え、前記隙間には、前記第２の樹脂体を構成する樹脂が前記複数のコア部材に密着して介在し、前記ケースは、底板と、前記底板と一体に設けられた対向する前壁および後壁と、前記前壁および前記後壁を繋ぐとともに、第２の開口部が設けられた側壁を有し、前記第２の樹脂体は、前記第２の開口部を塞ぐ左右の壁を有し、前記左右の壁が前記第２の開口部の縁と接合されていること、を特徴とする。
さらに、本発明のコアユニットは、複数のコア部材がそのプレス方向に沿って隙間を空けて配列されてなる第２のコアと、前記第２のコアを収容するケースと、前記複数のコア部材の周囲の少なくとも一部を被覆するとともに、当該複数のコア部材を固定して前記第２のコアを構成し、かつ、前記ケースと接合された第２の樹脂体と、を備え、前記隙間には、前記第２の樹脂体を構成する樹脂が前記複数のコア部材に密着して介在し、前記第２の樹脂体には、前記隙間の部分に前記第２の樹脂体を構成する樹脂の注入痕が設けられ、前記ケースは、前記注入痕を介在させて対向するとともに、前記プレス方向と直交する前記コア部材の直交面と対向する内壁に、前記直交面に向けて突出した突起が設けられていること、を特徴とする。 Further, the core unit of the present invention includes a second core in which a plurality of core members are arranged with a gap along the pressing direction, a case for accommodating the second core, and the plurality of core members. The second core is formed by covering at least a part of the periphery of the case and fixing the plurality of core members, and the second resin body joined to the case is provided in the gap. The resin constituting the second resin body is interposed in close contact with the plurality of core members, and the case includes a bottom plate, facing front walls and rear walls integrally provided with the bottom plate, and the case. The second resin body has left and right walls that connect the front wall and the rear wall and is provided with a second opening, and the left and right walls are closed. It is characterized in that the wall is joined to the edge of the second opening .
Further, the core unit of the present invention includes a second core in which a plurality of core members are arranged with a gap along the pressing direction, a case for accommodating the second core, and the plurality of core members. The second core is formed by covering at least a part of the periphery of the case and fixing the plurality of core members, and the second resin body joined to the case is provided in the gap. In the second resin body, the resin constituting the second resin body is in close contact with the plurality of core members, and the resin constituting the second resin body is formed in the gap portion of the second resin body. An injection mark is provided, and the case is provided with the injection mark interposed therebetween and facing the inner wall facing the orthogonal surface of the core member orthogonal to the pressing direction, and a protrusion protruding toward the orthogonal surface is provided on the inner wall. It is characterized by being done.

本発明のリアクトルは、前記第１のコアを有するコアユニットを第１のコアユニット、前記第２のコアを有するコアユニットを第２のコアユニットとすると、第１のコアユニットと第２のコアユニットとを備え、前記第１のコアユニットが前記ケースに収容され、前記第１のコアと前記第２のコアが接合されて環状コアを構成していること、を特徴とする。 In the reactor of the present invention, assuming that the core unit having the first core is the first core unit and the core unit having the second core is the second core unit, the first core unit and the second core It is characterized in that the first core unit is housed in the case, and the first core and the second core are joined to form an annular core.

本発明によれば、コアのプレス方向の大きさの制約を受けず、コア内部の熱を放熱することのできるコアユニット及びリアクトルを得ることができる。 According to the present invention, it is possible to obtain a core unit and a reactor capable of dissipating heat inside the core without being restricted by the size of the core in the pressing direction.

第１の実施形態に係るリアクトルの全体斜視図である。It is an overall perspective view of the reactor which concerns on 1st Embodiment. 第１の実施形態に係るリアクトルの分解斜視図である。It is an exploded perspective view of the reactor which concerns on 1st Embodiment. 第１の実施形態に係るリアクトルの各ユニットの構成を示す斜視図である。It is a perspective view which shows the structure of each unit of the reactor which concerns on 1st Embodiment. コアの構成を示す斜視図である。It is a perspective view which shows the structure of a core. ケースの上面側斜視図である。It is a top view side perspective view of a case. ケースの底面図である。It is a bottom view of the case. 上ユニットの底面側斜視図である。It is the bottom side perspective view of the upper unit. 下ユニットの上面側斜視図である。It is the top side perspective view of the lower unit. 下ユニットの底面側斜視図である。It is the bottom side perspective view of the lower unit. 下ユニットの製造工程を説明するための図であり、図９のＡ−Ａ断面を示す。It is a figure for demonstrating the manufacturing process of the lower unit, and shows the cross section AA of FIG. 下ユニットの製造工程を説明するための図であり、下コア及びケースの底面図を示す。It is a figure for demonstrating the manufacturing process of a lower unit, and shows the bottom view of a lower core and a case. 上ユニットの製造工程を説明するための図であり、図７のＢ−Ｂ断面箇所を示す。It is a figure for demonstrating the manufacturing process of the upper unit, and shows the BB cross-section part of FIG. 複数のコア部材とケースとを樹脂モールド成形する際の課題を説明するための図である。It is a figure for demonstrating the problem at the time of resin molding a plurality of core members and a case.

以下、図面を参照して、本発明の実施形態のリアクトルについて説明する。 Hereinafter, the reactor according to the embodiment of the present invention will be described with reference to the drawings.

［１．第１の実施形態］
［１−１．概略構成］
図１は、第１の実施形態に係るリアクトルの全体斜視図である。図２は、第１の実施形態に係るリアクトルの分解斜視図である。図３は、第１の実施形態に係るリアクトルの各ユニットの構成を示す斜視図である。 [1. First Embodiment]
[1-1. Outline configuration]
FIG. 1 is an overall perspective view of the reactor according to the first embodiment. FIG. 2 is an exploded perspective view of the reactor according to the first embodiment. FIG. 3 is a perspective view showing the configuration of each unit of the reactor according to the first embodiment.

リアクトルは、電気エネルギーを磁気エネルギーに変換して蓄積及び放出する電磁気部品であり、電圧の昇降圧等に使用される。本実施形態のリアクトルは、例えばハイブリッド自動車や電気自動車の駆動システム等で使用される大容量のリアクトルである。リアクトルは、これら自動車に搭載される昇圧回路の主要部品である。 The reactor is an electromagnetic component that converts electrical energy into magnetic energy and stores and discharges it, and is used for raising and lowering voltage. The reactor of the present embodiment is a large-capacity reactor used in, for example, a drive system of a hybrid vehicle or an electric vehicle. The reactor is the main component of the booster circuit installed in these automobiles.

図１〜図３に示すように、本実施形態に係るリアクトルは、コア１と、樹脂部材２と、ケース４と、コイル５と、充填成形部６とを備える。 As shown in FIGS. 1 to 3, the reactor according to the present embodiment includes a core 1, a resin member 2, a case 4, a coil 5, and a filling and forming portion 6.

コア１は、上コア１Ａと下コア１Ｂとから構成され、樹脂部材２は、上コア１Ａを被覆する上カバー２Ａと、下コア１Ｂを被覆する下カバー２Ｂとを有する。下カバー２Ｂが、下コア１Ｂとケース４とを一体化してコアユニットとして下ユニット１０Ｂを構成し、上コア１Ａと上カバー２Ａとでコアユニットとして上ユニット１０Ａを構成する。下ユニット１０Ｂの中脚部にコイル５を嵌め込み、上ユニット１０Ａを下ユニット１０Ｂに組み付け、ケース４内に充填材を充填及び固化して充填成形部６を構成することでリアクトルを構成する。 The core 1 is composed of an upper core 1A and a lower core 1B, and the resin member 2 has an upper cover 2A that covers the upper core 1A and a lower cover 2B that covers the lower core 1B. The lower cover 2B integrates the lower core 1B and the case 4 to form the lower unit 10B as a core unit, and the upper core 1A and the upper cover 2A form the upper unit 10A as a core unit. The coil 5 is fitted into the middle leg portion of the lower unit 10B, the upper unit 10A is assembled to the lower unit 10B, and the filler is filled and solidified in the case 4 to form the filling molding portion 6 to form a reactor.

［１−２．詳細構成］
本実施形態のリアクトルの各部の詳細構成について、図１〜図３の他、図４〜図９を用いて説明する。なお、本明細書において、図１に示すｚ軸方向を「上」側、その逆方向を「下」側とする。各部材の構成を説明するのに、「下」は「底」や「裏」とも称する。「上」や「下」とは、リアクトルの各構成の位置関係をいうものであり、リアクトルが実機に搭載された際の位置関係や方向を指すものではない。 [1-2. Detailed configuration]
The detailed configuration of each part of the reactor of the present embodiment will be described with reference to FIGS. 4 to 9 in addition to FIGS. 1 to 3. In the present specification, the z-axis direction shown in FIG. 1 is referred to as the "upper" side, and the opposite direction is referred to as the "lower" side. To explain the configuration of each member, "bottom" is also referred to as "bottom" or "back". The "upper" and "lower" refer to the positional relationship of each configuration of the reactor, and do not refer to the positional relationship or direction when the reactor is mounted on the actual machine.

コア１は、磁性粉末を含む磁性材料を金型に入れてプレスしてなる環状コアである。コア１としては、圧粉磁心、メタルコンポジットコアを用いることができる。圧粉磁心は、磁性粉末と樹脂とを含む磁性材料を金型に入れてプレスして成形した成形体を焼鈍処理してなるコアである。メタルコンポジットコアは、磁性粉末と樹脂とを含む磁性材料を金型に入れてプレスして成形してなるコアであり、焼鈍処理されていないコアである。ここでは、コア１は圧粉磁心である。 The core 1 is an annular core formed by placing a magnetic material containing magnetic powder in a mold and pressing it. As the core 1, a dust core or a metal composite core can be used. The dust core is a core formed by annealing a molded product formed by putting a magnetic material containing magnetic powder and a resin into a mold and pressing it. The metal composite core is a core formed by putting a magnetic material containing magnetic powder and resin in a mold and pressing it to form a core, which has not been annealed. Here, the core 1 is a dust core.

図４に示すように、コア１は、上コア１Ａと下コア１Ｂとが接合されて構成される。上コア１Ａおよび下コア１Ｂは、複数のコア部材がそのプレス方向に沿って隙間１９を空けて配列されてなる。ここでは、コア部材はプレス方向に直交する直交面がＥ字形状を成すＥ字型コアであり、同じＥ字型コアを用いる。上コア１Ａのコア部材に符号１１、１２を付し、下コア１Ｂのコア部材に符号１３、１４を付す。ここでは、プレス方向は、ｙ方向であり、コア部材の密度均一化の観点から、後述の各脚１５〜１７の延び方向と直交する方向としている。また、図４に示すように、直交面は、ｘｚ平面に平行な面である。コア部材には、平行な直交面の間の側周面に、直交面と略直交する方向に延びるキズがあっても良い。 As shown in FIG. 4, the core 1 is configured by joining the upper core 1A and the lower core 1B. The upper core 1A and the lower core 1B are formed by arranging a plurality of core members with a gap 19 along the pressing direction thereof. Here, the core member is an E-shaped core in which orthogonal planes orthogonal to the press direction form an E-shape, and the same E-shaped core is used. Reference numerals 11 and 12 are attached to the core members of the upper core 1A, and reference numerals 13 and 14 are attached to the core members of the lower core 1B. Here, the pressing direction is the y direction, which is orthogonal to the extending direction of each of the legs 15 to 17, which will be described later, from the viewpoint of making the density of the core member uniform. Further, as shown in FIG. 4, the orthogonal plane is a plane parallel to the xz plane. The core member may have scratches extending in a direction substantially orthogonal to the orthogonal planes on the side peripheral planes between the parallel orthogonal planes.

Ｅ字型コア１１〜１４は、中央の中脚１５と、中脚１５の両側に中脚１５と平行に設けられた外脚１６、１７と、各脚１５〜１７を繋ぐヨーク１８とから構成される。上コア１Ａは、Ｅ字型コア１１、１２が互いの直交面が平行かつ各脚１５〜１７が揃うように、ｙ方向に隙間１９を空けて配列されて成り、下コア１Ｂは、Ｅ字型コア１３、１４が互いの直交面が平行かつ各脚１５〜１７が揃うように、ｙ方向に隙間１９を空けて配列されて成る。 The E-shaped cores 11 to 14 are composed of a central middle leg 15, outer legs 16 and 17 provided on both sides of the middle leg 15 in parallel with the middle leg 15, and a yoke 18 connecting the respective legs 15 to 17. Will be done. The upper core 1A is formed by arranging the E-shaped cores 11 and 12 with a gap 19 in the y direction so that the orthogonal planes of the E-shaped cores 11 and 12 are parallel to each other and the legs 15 to 17 are aligned, and the lower core 1B is an E-shaped core. The mold cores 13 and 14 are arranged with a gap 19 in the y direction so that their orthogonal planes are parallel to each other and the legs 15 to 17 are aligned.

上コア１Ａ及び下コア１Ｂは、中脚１５が、コイル５が装着される中脚部を構成し、外脚１６、１７が外脚部を構成し、ヨーク１８がヨーク部を構成する。なお、上コア１Ａおよび下コア１Ｂの外脚１６、１７は、端面同士が当接して接着剤等により接合され、上コア１Ａおよび下コア１Ｂの中脚１５は端面同士が離れており、ギャップが存在する。 In the upper core 1A and the lower core 1B, the middle leg 15 constitutes the middle leg portion to which the coil 5 is mounted, the outer legs 16 and 17 form the outer leg portion, and the yoke 18 constitutes the yoke portion. The outer legs 16 and 17 of the upper core 1A and the lower core 1B are in contact with each other and are joined by an adhesive or the like, and the middle legs 15 of the upper core 1A and the lower core 1B are separated from each other and have a gap. Exists.

このように、コア１は、概略θ形状をなし、コイル５が装着される中脚部と、中脚部の両側に中脚部と平行に延びる一対の外脚部と、中脚部および外脚部を繋ぐヨーク部とからなる。コイル５が通電するとコイル５の空芯部に磁束が発生し、発生した磁束は中脚部からヨーク部、外脚部を介して中脚部に戻って閉じた磁路を形成する。 As described above, the core 1 has a substantially θ shape, and has a middle leg portion to which the coil 5 is mounted, a pair of outer leg portions extending in parallel with the middle leg portion on both sides of the middle leg portion, and a middle leg portion and an outer leg portion. It consists of a yoke part that connects the legs. When the coil 5 is energized, a magnetic flux is generated in the air core portion of the coil 5, and the generated magnetic flux returns from the middle leg portion to the middle leg portion via the yoke portion and the outer leg portion to form a closed magnetic path.

なお、コア１に形成される磁路とＥ字型コア１１〜１４の直交面とは平行である。そのため、本実施形態のように、プレス方向（ｙ方向）にコア部材を配列しても、磁路内のギャップにはなりにくく、磁気特性への影響は小さい。 The magnetic path formed in the core 1 and the orthogonal planes of the E-shaped cores 11 to 14 are parallel to each other. Therefore, even if the core members are arranged in the press direction (y direction) as in the present embodiment, the gap in the magnetic path is unlikely to occur, and the influence on the magnetic characteristics is small.

ケース４は、コア１およびコイル５を収容する収容体である。ケース４は、例えばアルミニウム合金等、熱伝導性が高く軽量な金属で構成されており、放熱性を有する。 Case 4 is an accommodating body for accommodating the core 1 and the coil 5. The case 4 is made of a lightweight metal having high thermal conductivity, such as an aluminum alloy, and has heat dissipation.

図２、図５及び図６に示すように、ケース４は、上面が開口した概略直方体形状であり、底板４１と底板４１と一体に設けられた対向する前壁４２、後壁４３、及び前壁４２と後壁４３とを繋ぐ側壁４４を有する。底板４１および側壁４４には、開口部４７、４８が設けられている。底板４１は矩形状であり、中央に開口部４７が設けられ、側壁４４は、矩形の一部が切り欠かれるようにして矩形状の開口部４８が設けられて、底板４１と一連のｙ方向に延びる辺と、当該辺の両端からｚ方向に延びて前壁４２、後壁４３と一連の辺とからなるＵ字形状を成す。前壁４２及び後壁４３は、互いに平行でｙ方向に肉厚な略矩形状の壁である。ケース４内にＥ字型コア１１〜１４が配置された際、前壁４２及び後壁４３の内周はＥ字型コア１１〜１４の直交面と対向する。前壁４２及び後壁４３の内周がケース４のＥ字型コア１１〜１４の直交面と対向する内壁となる。 As shown in FIGS. 2, 5 and 6, the case 4 has a substantially rectangular parallelepiped shape with an open upper surface, and has an opposite front wall 42, a rear wall 43, and a front wall integrally provided with the bottom plate 41 and the bottom plate 41. It has a side wall 44 connecting the wall 42 and the rear wall 43. The bottom plate 41 and the side wall 44 are provided with openings 47 and 48. The bottom plate 41 has a rectangular shape, an opening 47 is provided in the center, and the side wall 44 is provided with a rectangular opening 48 so that a part of the rectangle is cut out, and the bottom plate 41 and a series of y-directions are provided. It forms a U-shape consisting of a side extending in the z direction, a front wall 42 extending in the z direction from both ends of the side, a rear wall 43, and a series of sides. The front wall 42 and the rear wall 43 are substantially rectangular walls that are parallel to each other and thick in the y direction. When the E-shaped cores 11 to 14 are arranged in the case 4, the inner circumferences of the front wall 42 and the rear wall 43 face the orthogonal planes of the E-shaped cores 11 to 14. The inner circumferences of the front wall 42 and the rear wall 43 are the inner walls facing the orthogonal planes of the E-shaped cores 11 to 14 of the case 4.

前壁４２及び後壁４３の内周には、突起４０が設けられている。前壁４２の突起４０と後壁４３の突起４０とは対向して設けられている。突起４０は、Ｅ字型コア１１〜１４の外脚１６、１７に向けて突出しており、先端が外脚１６、１７の外表面に当接する。また、突起４０は、外脚１６、１７がヨーク１８から延びる方向、すなわちｚ方向に延びている。 Protrusions 40 are provided on the inner circumferences of the front wall 42 and the rear wall 43. The protrusion 40 on the front wall 42 and the protrusion 40 on the rear wall 43 are provided so as to face each other. The protrusion 40 projects toward the outer legs 16 and 17 of the E-shaped cores 11 to 14, and the tip thereof abuts on the outer surface of the outer legs 16 and 17. Further, the protrusion 40 extends in the direction in which the outer legs 16 and 17 extend from the yoke 18, that is, in the z direction.

前壁４２及び後壁４３には、コイル５と対面する内壁部分に凹部４５が設けられている。凹部４５の形状は、コイル５の形状に倣った形状を有していても良い。凹部４５には、底板４１から壁４２、４３の上端までの間の高さに隆起した段部４６が底板４１の対角線上に設けられ、この端部４６に、上コア１Ａをケース４に固定するためのネジ穴４６ａが設けられている。 The front wall 42 and the rear wall 43 are provided with a recess 45 in the inner wall portion facing the coil 5. The shape of the recess 45 may have a shape that follows the shape of the coil 5. In the recess 45, a step portion 46 raised to a height between the bottom plate 41 and the upper ends of the walls 42 and 43 is provided diagonally of the bottom plate 41, and the upper core 1A is fixed to the case 4 at the end portion 46. A screw hole 46a is provided for this purpose.

図２に示すように、樹脂部材２は、コア部材の周囲を被覆してコア１を構成するとともに、ケース４と接合される。樹脂部材２は、上コア１Ａ周囲の少なくとも一部を被覆する上カバー２Ａと、下コア１Ｂ周囲の少なくとも一部を被覆する下カバー２Ｂとを有する。上カバー２Ａおよび下カバー２Ｂは、それぞれ樹脂で構成される樹脂体である。樹脂としては、例えば、エポキシ樹脂、不飽和ポリエステル系樹脂、ウレタン樹脂、ＢＭＣ（ＢｕｌｋＭｏｌｄｉｎｇＣｏｍｐｏｕｎｄ）、ＰＰＳ（ＰｏｌｙｐｈｅｎｙｌｅｎｅＳｕｌｆｉｄｅ）、ＰＢＴ（ＰｏｌｙｂｕｔｙｌｅｎｅＴｅｒｅｐｈｔｈａｌａｔｅ）等を用いることができる。 As shown in FIG. 2, the resin member 2 covers the periphery of the core member to form the core 1 and is joined to the case 4. The resin member 2 has an upper cover 2A that covers at least a part around the upper core 1A, and a lower cover 2B that covers at least a part around the lower core 1B. The upper cover 2A and the lower cover 2B are resin bodies composed of resin, respectively. As the resin, for example, an epoxy resin, an unsaturated polyester resin, a urethane resin, a BMC (Bulk Molding Compound), a PPS (Polyphenylene sulfide), a PBT (Polybutylene terephlate) and the like can be used.

上カバー２Ａは、上コア１Ａの周囲の少なくとも一部を被覆する。図７に示すように、上カバー２Ａは、Ｅ字型コア１１、１２の周囲を被覆して、これらＥ字型コア１１、１２を、そのプレス方向に隙間１９を空けて配列した状態で固定し、上コア１Ａを構成する。但し、Ｅ字型コア１１、１２の隙間１９には、上カバー２Ａを構成する樹脂が介在している。 The upper cover 2A covers at least a part around the upper core 1A. As shown in FIG. 7, the upper cover 2A covers the periphery of the E-shaped cores 11 and 12, and these E-shaped cores 11 and 12 are fixed in a state of being arranged with a gap 19 in the pressing direction thereof. Then, the upper core 1A is configured. However, the resin constituting the upper cover 2A is interposed in the gap 19 of the E-shaped cores 11 and 12.

上カバー２Ａには、Ｅ字型コア１１、１２の隙間１９の部分に樹脂の注入痕３０Ａと、Ｅ字型コア１１、１２のプレス方向と直交する直交面を露出させる一対の開口部２１とが設けられている。注入痕３０Ａは、上カバー２Ａ（樹脂部材２）を構成する樹脂が注入され、当該樹脂が固化した際に形成された跡であり、凹凸などによりなる。一対の開口部２１は、注入痕３０Ａを介在させて対向する。ここでは、開口部２１は、矩形状の開口であり、直交面の中脚１５及びヨーク部１８の部分を露出する。注入痕３０Ａと一対の開口部２１は、図２及び図３に示すように、同一直線上に設けられている。また、上カバー２Ａには、中脚１５、外脚１６、１７の端面、及び外脚１６、１７の内外の側面が露出する開口が設けられている。 The upper cover 2A has a resin injection mark 30A in the gap 19 of the E-shaped cores 11 and 12, and a pair of openings 21 that expose an orthogonal surface orthogonal to the pressing direction of the E-shaped cores 11 and 12. Is provided. The injection mark 30A is a mark formed when the resin constituting the upper cover 2A (resin member 2) is injected and the resin is solidified, and is formed by unevenness or the like. The pair of openings 21 face each other with the injection mark 30A interposed therebetween. Here, the opening 21 is a rectangular opening, and the portions of the middle leg 15 and the yoke portion 18 on the orthogonal plane are exposed. The injection mark 30A and the pair of openings 21 are provided on the same straight line as shown in FIGS. 2 and 3. Further, the upper cover 2A is provided with an opening in which the end faces of the middle leg 15, the outer legs 16 and 17, and the inner and outer side surfaces of the outer legs 16 and 17 are exposed.

また、上カバー２Ａには、段部４６に載置され、上コア１Ａをケース４に固定するための不図示の固定部が設けられており、この固定部にネジ挿入孔が設けられている。ネジ挿入孔にネジ９１が挿入されネジ締結されることで、上コア１Ａがケース４に対して固定される。 Further, the upper cover 2A is provided with a fixing portion (not shown) mounted on the step portion 46 and for fixing the upper core 1A to the case 4, and the fixing portion is provided with a screw insertion hole. .. The upper core 1A is fixed to the case 4 by inserting the screw 91 into the screw insertion hole and fastening the screw.

図２、図８及び図９に示すように、下カバー２Ｂは、Ｅ字型コア１３、１４の周囲を被覆する被覆部２３と、Ｅ字型コア１３、１４の外脚１６、１７の外側に立設した左右の壁２４と、左右の壁２４の両端部に設けられた張出部２５とを有する。 As shown in FIGS. 2, 8 and 9, the lower cover 2B has a covering portion 23 that covers the periphery of the E-shaped cores 13 and 14 and the outer side of the outer legs 16 and 17 of the E-shaped cores 13 and 14. It has left and right walls 24 erected on the left and right walls 24, and overhanging portions 25 provided at both ends of the left and right walls 24.

被覆部２３は、Ｅ字型コア１３、１４の周囲を被覆して、これらＥ字型コア１３、１４を、そのプレス方向に隙間１９を空けて配列した状態で固定し、下コア１Ｂを構成する。但し、Ｅ字型コア１３、１４の隙間１９には、下カバー２Ｂを構成する樹脂が介在しており、Ｅ字型コア１３、１４が固定され、また、この樹脂はケース４の接合部分と一続きに成っている。被覆部２３は、開口部４７を塞いでおり、開口部４７を塞ぐ面と底板４１の底面はそれぞれ面一になっている。また、被覆部２３には、外脚１６、１７の端面、及び外脚１６、１７の内側面が露出する開口が設けられている。 The covering portion 23 covers the periphery of the E-shaped cores 13 and 14 and fixes the E-shaped cores 13 and 14 in a state of being arranged with a gap 19 in the pressing direction thereof to form the lower core 1B. do. However, the resin constituting the lower cover 2B is interposed in the gap 19 of the E-shaped cores 13 and 14, and the E-shaped cores 13 and 14 are fixed, and this resin is connected to the joint portion of the case 4. It is made up of a series. The covering portion 23 closes the opening 47, and the surface closing the opening 47 and the bottom surface of the bottom plate 41 are flush with each other. Further, the covering portion 23 is provided with an opening in which the end faces of the outer legs 16 and 17 and the inner side surfaces of the outer legs 16 and 17 are exposed.

被覆部２３には、開口部４７を塞ぐ部分に注入痕３０Ｂが設けられている。注入痕３０Ｂは、下カバー２Ｂ（樹脂部材２）を構成する樹脂が注入され、当該樹脂が固化した際に形成された跡であり、凹凸などによりなる。この注入痕３０Ｂは、開口部４７を塞ぐ被覆部２３の底面において、Ｅ字型コア１３、１４間の隙間の部分に設けられる。より詳細には、注入痕３０Ｂは、前壁４２に設けられた突起４０と後壁４３に設けられた突起４０とを結ぶ直線上であって、Ｅ字型コア１３、１４間の隙間の部分に設けられる。 The covering portion 23 is provided with an injection mark 30B at a portion that closes the opening 47. The injection mark 30B is a mark formed when the resin constituting the lower cover 2B (resin member 2) is injected and the resin is solidified, and is formed by unevenness or the like. The injection mark 30B is provided in the gap portion between the E-shaped cores 13 and 14 on the bottom surface of the covering portion 23 that closes the opening 47. More specifically, the injection mark 30B is on a straight line connecting the protrusion 40 provided on the front wall 42 and the protrusion 40 provided on the rear wall 43, and is a portion of a gap between the E-shaped cores 13 and 14. It is provided in.

左右の壁２４は、略四角形状の板状体であり、前壁４２および後壁４３の間に設けられている。左右の壁２４は、側壁４４の開口部４８を塞いで側壁４４の開口部４８の縁と接合されている。左右の壁２４は、側壁４４の表面と面一になっている。 The left and right walls 24 are substantially square plate-shaped bodies, and are provided between the front wall 42 and the rear wall 43. The left and right walls 24 close the opening 48 of the side wall 44 and are joined to the edge of the opening 48 of the side wall 44. The left and right walls 24 are flush with the surface of the side wall 44.

張出部２５は、左右の壁２４の両端に設けられ、開口部４８の縁からケース４の内側に張り出している。張出部２５は、側壁４４及び前壁４２又は後壁４３の形状に倣った形状を有し、側壁４４、前壁４２、後壁４３と密着してこれら側壁４４、前壁４２、後壁４３と接合されている。具体的には、前壁４２側の張出部２５は、側壁４４及び前壁４２の内周に倣った形状を有し、側壁４４及び前壁４２と密着して接合されている。後壁４３側の張出部２５は、側壁４４及び後壁４３の内周に倣った形状を有し、側壁４４及び後壁４３と密着して接合されている。これにより、張出部２５は、充填材又は充填成形部６の熱膨張による左右の壁２４の外側への倒れを防止する。 The overhanging portions 25 are provided at both ends of the left and right walls 24, and overhang from the edges of the openings 48 to the inside of the case 4. The overhanging portion 25 has a shape that follows the shape of the side wall 44 and the front wall 42 or the rear wall 43, and is in close contact with the side wall 44, the front wall 42, and the rear wall 43, and these side walls 44, the front wall 42, and the rear wall. It is joined with 43. Specifically, the overhanging portion 25 on the front wall 42 side has a shape that follows the inner circumference of the side wall 44 and the front wall 42, and is closely joined to the side wall 44 and the front wall 42. The overhanging portion 25 on the rear wall 43 side has a shape that follows the inner circumference of the side wall 44 and the rear wall 43, and is closely joined to the side wall 44 and the rear wall 43. As a result, the overhanging portion 25 prevents the left and right walls 24 from falling outward due to thermal expansion of the filler or the filling molding portion 6.

コイル５は、絶縁被覆を有する導線である。本実施形態では、コイル５は、平角線のエッジワイズコイルである。但し、コイル５の線材や巻き方は平角線のエッジワイズコイルに限定されず、他の形態であっても良い。 The coil 5 is a conducting wire having an insulating coating. In this embodiment, the coil 5 is a flat wire edgewise coil. However, the wire material and winding method of the coil 5 are not limited to the edgewise coil of the flat wire, and may be in other forms.

図３に示すように、コイル５は、巻軸を開口部４７に向けてケース４に配置され、コア１の中脚部に装着される。コイル５の両端部は、例えば上方などのリアクトル外部に引き出されており、外部電源などの外部機器の配線と接続される。 As shown in FIG. 3, the coil 5 is arranged in the case 4 with the winding shaft facing the opening 47, and is mounted on the middle leg portion of the core 1. Both ends of the coil 5 are drawn out to the outside of the reactor, for example, above, and are connected to the wiring of an external device such as an external power supply.

充填成形部６は、ケース４が囲うコア１の収容空間の隙間に充填材が充填及び固化されてなる。充填材には、リアクトルの放熱性能の確保及びリアクトルからケースへの振動伝搬の軽減のため、比較的柔らかく熱伝導性の高い樹脂が適している。また、充填材は絶縁性を有することが好ましい。 The filling molding unit 6 is formed by filling and solidifying a filler in the gap of the accommodating space of the core 1 surrounded by the case 4. As the filler, a resin that is relatively soft and has high thermal conductivity is suitable for ensuring the heat dissipation performance of the reactor and reducing the vibration propagation from the reactor to the case. Further, it is preferable that the filler has an insulating property.

［１−３．リアクトルの製造方法］
図３の他、図１０〜図１２を用いて本リアクトルの製造方法について説明する。本リアクトルは、下ユニット１０Ｂの製造工程、上ユニット１０Ａの製造工程、及び組立工程を有する。 [1-3. Reactor manufacturing method]
In addition to FIG. 3, a method for manufacturing the present reactor will be described with reference to FIGS. 10 to 12. The reactor has a manufacturing process for the lower unit 10B, a manufacturing process for the upper unit 10A, and an assembly process.

（１）下ユニット１０Ｂの製造工程
下ユニット１０Ｂは、上下が逆になった形で成型される。まず、図１０（ａ）に示すように、下型７１にインサート品として、ケース４及びＥ字型コア１３、１４をセットする。この時Ｅ字型コア１３、１４は、Ｅ字形状を成す面を平行にして、プレス方向に隙間を空けて、脚１５〜１７を下にして下型７１に配置する。このとき外脚１６、１７と突起４０とが接していても良いし、接していなくても良い。ここでは、Ｅ字型コア１３、ｌ４を下型７１にセットした段階では、外脚１６、１７が突起４０と接していないものとして説明する。 (1) Manufacturing Process of Lower Unit 10B The lower unit 10B is molded upside down. First, as shown in FIG. 10A, the case 4 and the E-shaped cores 13 and 14 are set in the lower mold 71 as insert products. At this time, the E-shaped cores 13 and 14 are arranged on the lower mold 71 with the E-shaped surfaces parallel to each other, with a gap in the pressing direction, and the legs 15 to 17 facing down. At this time, the outer legs 16 and 17 may or may not be in contact with each other. Here, it is assumed that the outer legs 16 and 17 are not in contact with the protrusion 40 when the E-shaped cores 13 and l4 are set in the lower mold 71.

次に、図１０（ｂ）に示すように、上型７２をセットする。上型７２には、樹脂を注入する貫通孔であるゲート７３が設けられている。このゲート７３は、図１１に示すように、Ｅ字型コア１３、１４の隙間１９に配置されている。ここでは、ゲート７３は、当該隙間１９に沿って間隔を空けて２箇所設けられている。但し、ゲート７３の数は、ゲート７３が当該隙間１９に沿って設けられるのであれば、特に限定されず、１つでも３つ以上でも良い。 Next, as shown in FIG. 10 (b), the upper mold 72 is set. The upper mold 72 is provided with a gate 73, which is a through hole for injecting resin. As shown in FIG. 11, the gate 73 is arranged in the gap 19 of the E-shaped cores 13 and 14. Here, the gate 73 is provided at two locations at intervals along the gap 19. However, the number of gates 73 is not particularly limited as long as the gates 73 are provided along the gap 19, and may be one or three or more.

図１０（ｂ）の黒塗り矢印に示すように、ゲート７３から樹脂を注入し、樹脂がＥ字型コア１３、１４の隙間に充填されると、Ｅ字型コア１３、１４には、図１０（ｂ）の白抜き矢印に示すように、樹脂の射出圧が互いに離れようとする方向に働く。ここで、突起４０が、２つのＥ字型コア１３、１４の外脚１６、１７を挟むようにして対向して、ケース４の前壁４２および後壁４３の内面に設けられているため、Ｅ字型コア１３、１４が離れる方向に移動しても、Ｅ字型コア１３、１４は突起４０と当接して押さえられて、下型７１又は上型７２の内壁に当接することがない。突起４０は、下型７１又は上型７２の内壁の突出部分よりも突出しているからである。このようにして、金型に配置するケース４によって同じく金型に配置するＥ字型コア１３、１４を支持する。 As shown by the black arrow in FIG. 10B, when the resin is injected from the gate 73 and the resin is filled in the gaps between the E-shaped cores 13 and 14, the E-shaped cores 13 and 14 are shown in the figure. As shown by the white arrow in 10 (b), the injection pressures of the resins act in the direction in which they tend to separate from each other. Here, since the protrusions 40 are provided on the inner surfaces of the front wall 42 and the rear wall 43 of the case 4 so as to face each other so as to sandwich the outer legs 16 and 17 of the two E-shaped cores 13 and 14, they are E-shaped. Even if the mold cores 13 and 14 move away from each other, the E-shaped cores 13 and 14 are in contact with the protrusions 40 and pressed, and do not abut on the inner wall of the lower mold 71 or the upper mold 72. This is because the protrusion 40 protrudes from the protruding portion of the inner wall of the lower mold 71 or the upper mold 72. In this way, the E-shaped cores 13 and 14 also arranged in the mold are supported by the case 4 arranged in the mold.

金型内の樹脂の充填後、固化させて、下カバー２Ｂを形成して下コア１Ｂとケース４とを一体化し、下ユニット１０を構成する。そして、下ユニット１０を金型内から取り出す。なお、被覆部２３に設けられた開口は、Ｅ字型コア１３、１４が下型７１に当接された状態で樹脂が充填されたため被覆されずに形成されたものである。このように、樹脂をヨーク１８側から注入し、樹脂の射出圧によりＥ字型コア１３、１４をヨーク１８側から押しつけ、外脚１６、１７を下型７１に当てることで、ケース４の開口部４７から露出するヨーク１８側を樹脂で覆うことができ、リアクトルの設置面に対する絶縁を確保することができる。 After filling the resin in the mold, it is solidified to form the lower cover 2B, and the lower core 1B and the case 4 are integrated to form the lower unit 10. Then, the lower unit 10 is taken out from the mold. The opening provided in the covering portion 23 is formed without being covered because the E-shaped cores 13 and 14 are filled with resin in a state of being in contact with the lower mold 71. In this way, the resin is injected from the yoke 18 side, the E-shaped cores 13 and 14 are pressed from the yoke 18 side by the injection pressure of the resin, and the outer legs 16 and 17 are applied to the lower mold 71 to open the case 4. The side of the yoke 18 exposed from the portion 47 can be covered with resin, and insulation with respect to the installation surface of the reactor can be ensured.

樹脂の固化後、ゲート７３の位置に注入痕３０Ｂが形成される。この注入痕３０Ｂは、Ｅ字型コア１３、１４の隙間１９の部分であって、前壁４２の突起４０と後壁４３の突起４０との中間位置に形成される。なお、下カバー２Ｂには、Ｅ字型コア１３、１４に突起４０が当接する部分に凹部が形成される。 After the resin is solidified, an injection mark 30B is formed at the position of the gate 73. The injection mark 30B is a portion of the gap 19 of the E-shaped cores 13 and 14, and is formed at an intermediate position between the protrusion 40 of the front wall 42 and the protrusion 40 of the rear wall 43. The lower cover 2B is formed with a recess in a portion where the protrusion 40 abuts on the E-shaped cores 13 and 14.

（２）上ユニット１０Ａの製造工程
図１２に示すように、Ｅ字型コア１１、１２の脚１５〜１７を下型８１の凹部に挿入し、下型８１にＥ字型コア１１、１２をセットする。この状態では、Ｅ字型コア１１、１２は、Ｅ字型コア１１、１２の間に隙間が設けられ、Ｅ字形状を成す面が平行に配列されている。 (2) Manufacturing process of the upper unit 10A As shown in FIG. 12, the legs 15 to 17 of the E-shaped cores 11 and 12 are inserted into the recesses of the lower mold 81, and the E-shaped cores 11 and 12 are inserted into the lower mold 81. set. In this state, the E-shaped cores 11 and 12 are provided with a gap between the E-shaped cores 11 and 12, and the surfaces forming the E-shaped core are arranged in parallel.

次に、上型８２をセットする。このとき、金型又は治具８４によりＥ字型コア１１、１２を押さえてｘｙ方向に位置決めする。さらに、上型８２に貫通孔であるゲート８３から金型内に樹脂を充填する。ゲート８３は、Ｅ字型コア１１、１２の隙間１９に設けられており、ここでは、１箇所設けられている。樹脂の射出圧により、Ｅ字型コア１１、１２は、下型８１に押しつけられ、外脚１６、１７の端面には樹脂が被覆されない。また、下型８１の凹部と接触することにより、外脚１６、１７の外表面および内表面にも樹脂は被覆されない。また、中脚１５及びヨーク１８の表面も金型又は治具８４により押さえられるため、樹脂は被覆されない。そのため、一対の開口部２１が形成される。 Next, the upper mold 82 is set. At this time, the E-shaped cores 11 and 12 are pressed by the mold or the jig 84 and positioned in the xy direction. Further, the upper mold 82 is filled with resin from the gate 83, which is a through hole, into the mold. The gate 83 is provided in the gap 19 of the E-shaped cores 11 and 12, and is provided at one place here. The E-shaped cores 11 and 12 are pressed against the lower mold 81 by the injection pressure of the resin, and the end faces of the outer legs 16 and 17 are not covered with the resin. Further, the resin is not coated on the outer surface and the inner surface of the outer legs 16 and 17 by coming into contact with the concave portion of the lower mold 81. Further, since the surfaces of the middle leg 15 and the yoke 18 are also pressed by the mold or the jig 84, the resin is not coated. Therefore, a pair of openings 21 are formed.

樹脂の固化後、ゲート８３の位置に注入痕３０Ａが形成され、注入痕３０Ａと一対の開口部２１は同一直線上に並ぶ。 After the resin is solidified, an injection mark 30A is formed at the position of the gate 83, and the injection mark 30A and the pair of openings 21 are aligned on the same straight line.

このように、樹脂をヨーク１８側から注入し、樹脂の射出圧によりＥ字型コア１１、１２をヨーク１８側から押しつけ、外脚１６、１７を下型８１に当てることで、ヨーク１８側を樹脂で覆うことができ、コアの防錆効果や絶縁を確保することができる。 In this way, the resin is injected from the yoke 18 side, the E-shaped cores 11 and 12 are pressed from the yoke 18 side by the injection pressure of the resin, and the outer legs 16 and 17 are applied to the lower mold 81 to press the yoke 18 side. It can be covered with resin, and the rust preventive effect and insulation of the core can be ensured.

以上のように金型内の樹脂の充填後、固化させることで上ユニット１０Ａを形成し、金型又は治具８４をｘｙ方向にスライドさせ、上ユニット１０Ａを金型内から取り出す。これにより、金型又は治具８４との摺動によるキズがＥ字型コア１１、１２に生じることがなくなる。 After filling the resin in the mold as described above, the upper unit 10A is formed by solidifying the resin, the mold or the jig 84 is slid in the xy direction, and the upper unit 10A is taken out from the mold. As a result, the E-shaped cores 11 and 12 are not scratched due to sliding with the mold or the jig 84.

（３）組立工程
図３に示すように、下ユニット１０には、壁４２〜４４、２４によって四角い枠が区画され、コイル５の収容空間が形成されている。コイル５を下コア１Ｂの中脚部に嵌め込み、上ユニット１０Ａの中脚部をコイル５に挿入し、上コア１Ａの外脚１６、１７を下コア１Ｂの外脚１６、１７に接着剤等により接合する。上ユニット１０Ａを固定部を介してネジ締結によりケース４に組み付ける。そして、コイル５の収容空間に、充填材を充填及び固化させて、充填成形部６を形成し、リアクトルを得る。 (3) Assembly process As shown in FIG. 3, a square frame is partitioned by walls 42 to 44, 24 in the lower unit 10, and a storage space for the coil 5 is formed. The coil 5 is fitted into the middle leg portion of the lower core 1B, the middle leg portion of the upper unit 10A is inserted into the coil 5, and the outer legs 16 and 17 of the upper core 1A are attached to the outer legs 16 and 17 of the lower core 1B. Join with. The upper unit 10A is assembled to the case 4 by screwing via the fixing portion. Then, the filler is filled and solidified in the accommodating space of the coil 5 to form the filling and molding portion 6, and a reactor is obtained.

［１−４．作用・効果］
（１）本実施形態のコアユニットである上ユニット１０Ａは、Ｅ字型コア１１、１２がそのプレス方向に沿って隙間１９を空けて配列されてなる上コア１Ａと、Ｅ字型コア１１、１２の周囲の少なくとも一部を被覆するとともに、当該Ｅ字型コア１１、１２を固定して上コア１Ａを構成する第１の樹脂体である上カバー２Ａと、を備え、隙間１９には、上カバー２Ａを構成する樹脂がＥ字型コア１１、１２に密着して介在するようにした。 [1-4. Action / effect]
(1) The upper unit 10A, which is the core unit of the present embodiment, includes an upper core 1A in which E-shaped cores 11 and 12 are arranged with a gap 19 along the pressing direction thereof, and an E-shaped core 11. The gap 19 is provided with an upper cover 2A, which is a first resin body that covers at least a part of the periphery of the 12 and fixes the E-shaped cores 11 and 12 to form the upper core 1A. The resin constituting the upper cover 2A is made to adhere to and intervene in the E-shaped cores 11 and 12.

また、コアユニットである下ユニット１０Ｂは、Ｅ字型コア１３、１４がそのプレス方向に沿って隙間１９を空けて配列されてなる下コア１Ｂと、下コア１Ｂを収容するケース４と、Ｅ字型コア１３、１４の周囲の少なくとも一部を被覆するとともに、当該Ｅ字型コア１３、１４を固定して下コア１Ｂを構成し、かつ、ケース４と接合された下カバー２Ｂと、を備え、隙間１９には、下カバー２Ｂを構成する樹脂がＥ字型コア１３、１４に密着して介在するようにした。 Further, the lower unit 10B, which is a core unit, includes a lower core 1B in which E-shaped cores 13 and 14 are arranged with a gap 19 along the pressing direction, a case 4 accommodating the lower core 1B, and E. The lower cover 2B, which covers at least a part around the character-shaped cores 13 and 14 and fixes the E-shaped cores 13 and 14 to form the lower core 1B and is joined to the case 4, is attached. The gap 19 is provided with the resin constituting the lower cover 2B in close contact with the E-shaped cores 13 and 14.

これにより、プレス方向の寸法に制約を受けずに、プレス方向に大きなコアを得ることができる。また、コア部材間に密着して介在する樹脂により、コア部材間に空気層が生じる場合と比べて熱抵抗を低減させることができ、コア内部の熱を放熱することができる。さらに、複数のコア部材を接着剤等で接合する必要がなくなる。つまり、コア部材を接合する接着剤、およびその接着工程が必要ないので、製造コストおよび製造工数を削減することができる。 This makes it possible to obtain a large core in the press direction without being restricted by the dimensions in the press direction. In addition, the resin that is in close contact with the core members can reduce the thermal resistance as compared with the case where an air layer is formed between the core members, and the heat inside the core can be dissipated. Further, it is not necessary to join a plurality of core members with an adhesive or the like. That is, since the adhesive for joining the core members and the bonding process thereof are not required, the manufacturing cost and the manufacturing man-hours can be reduced.

このような効果の得られる上ユニット１０Ａの具体的構成として、上カバー２Ａに、隙間１９の部分に樹脂の注入痕３０Ａと、注入痕３０Ａを介在させて対向し、Ｅ字型コア１１、１２のプレス方向と直交する直交面を露出させる一対の開口部２１と、を設けるようにした。このような構成にすることにより、隙間１９の部分から樹脂を注入し、その射出圧により外側に移動しようとするＥ字型コア１１、１２を外側から金型又は治具で押さえる製造方法を採用することができる。当該製造方法において、ゲート８３と金型又は治具を同一直線上に配置することで、Ｅ字型コア１１、１２を金型又は治具で支えることができるので、安定的にコアユニットを製造することができる。また、開口部２１を設けたことで、上コア１Ａの熱を放熱することができる。 As a specific configuration of the upper unit 10A in which such an effect can be obtained, the resin injection marks 30A and the injection marks 30A are interposed at the upper cover 2A in the gap 19 so as to face each other, and the E-shaped cores 11 and 12 are opposed to each other. A pair of openings 21 for exposing an orthogonal surface orthogonal to the pressing direction of the above are provided. With such a configuration, a manufacturing method is adopted in which resin is injected from the portion of the gap 19 and the E-shaped cores 11 and 12 that try to move outward due to the injection pressure are pressed from the outside with a mold or a jig. can do. In the manufacturing method, by arranging the gate 83 and the mold or jig on the same straight line, the E-shaped cores 11 and 12 can be supported by the mold or jig, so that the core unit can be stably manufactured. can do. Further, by providing the opening 21, the heat of the upper core 1A can be dissipated.

（２）下カバー２Ｂには、隙間１９の部分に下カバー２Ｂを構成する樹脂の注入痕３０Ｂを設け、ケース４には、注入痕３０Ｂを介在させて対向するとともに、プレス方向と直交するＥ字型コア１３、１４の直交面と対向する内壁に、直交面に向けて突出した突起４０を設けるようにした。 (2) The lower cover 2B is provided with an injection mark 30B of the resin constituting the lower cover 2B in the gap 19, and the case 4 is opposed to the case 4 with the injection mark 30B interposed therebetween and is orthogonal to the pressing direction. A protrusion 40 protruding toward the orthogonal plane is provided on the inner wall of the character cores 13 and 14 facing the orthogonal plane.

これにより、Ｅ字型コア１３、１４間の隙間１９から樹脂を注入して樹脂モールド成形法により下コア１Ｂおよびケース４を一体化する際に、Ｅ字型コア１３、１４が樹脂の射出圧により互いに離れる方向に移動しようとするが、各突起４０がＥ字型コア１３、１４を支持するので、金型内壁にＥ字型コア１３、１４が当接することがない。このような構造によれば、下カバー２Ｂがプレス方向に大きくない複数のＥ字型コア１３、１４により、プレス方向に大きな下コア１Ｂを構成できるので、プレス方向の寸法に制約を受けずに、歩留まりの良いリアクトルを得ることができる。 As a result, when resin is injected from the gap 19 between the E-shaped cores 13 and 14 and the lower core 1B and the case 4 are integrated by the resin molding method, the E-shaped cores 13 and 14 have the injection pressure of the resin. However, since the protrusions 40 support the E-shaped cores 13 and 14, the E-shaped cores 13 and 14 do not come into contact with the inner wall of the mold. According to such a structure, the lower core 1B having a large size in the press direction can be formed by the plurality of E-shaped cores 13 and 14 whose lower cover 2B is not large in the press direction, so that the dimensions in the press direction are not restricted. , You can get a reactor with good yield.

すなわち、図１３に示すように、複数のコア部材１０１と複数のコア部材１０１を収容するケース１０４とを樹脂モールド成形法により一体成形したい場合に、金型１７１内にケース１０４および複数のコア部材１０１をセットして金型１７１内に樹脂を注入すると、その射出圧によりコア部材１０１が移動してしまい、金型１７１内壁に当接する場合がある。この当接状態で樹脂硬化後に金型１７１内から成形品を取り出そうとしても取り出せないか、取り出せてもコア表面にキズが発生し、歩留まりが悪化してしまう。 That is, as shown in FIG. 13, when it is desired to integrally mold the plurality of core members 101 and the case 104 accommodating the plurality of core members 101 by the resin molding method, the case 104 and the plurality of core members are contained in the mold 171. When the resin is injected into the mold 171 with the 101 set, the core member 101 may move due to the injection pressure and may come into contact with the inner wall of the mold 171. Even if the molded product is to be taken out from the mold 171 after the resin is cured in this contact state, it cannot be taken out, or even if it can be taken out, the core surface is scratched and the yield is deteriorated.

これに対し、本実施形態では、樹脂モールド成形対象とは別異の治具ではなく、樹脂モールド成形対象の１つであるケース４自体に突起４０を設けるようにしたので、樹脂の射出圧で外側に移動しようとするＥ字型コア１３、１４を突起４０で支えるため、Ｅ字型コア１３、１４が金型内壁に当接することがなくなる。その結果、Ｅ字型コア１３、１４の露出部分に金型内壁との摺動によるキズが付くのを防止でき、かつ、金型から成形品を取り出すことも可能である。結果として、歩留まりを良くすることができる。 On the other hand, in the present embodiment, the protrusion 40 is provided on the case 4 itself, which is one of the resin molding targets, instead of the jig different from the resin molding target, so that the injection pressure of the resin is used. Since the E-shaped cores 13 and 14 that are about to move outward are supported by the protrusions 40, the E-shaped cores 13 and 14 do not come into contact with the inner wall of the mold. As a result, it is possible to prevent the exposed portions of the E-shaped cores 13 and 14 from being scratched due to sliding with the inner wall of the mold, and it is also possible to take out the molded product from the mold. As a result, the yield can be improved.

（３）本実施形態のリアクトルは、上ユニット１０Ａと下ユニット１０Ｂとを備え、ケース４に収容され、上コア１Ａと下コア１Ｂが接合されて環状コアを構成するようにした。また、注入痕３０Ｂと突起４０は、同一直線上に設けるようにした。ここでは、本リアクトルを底面視して前壁４２の突起４０と、注入痕３０Ｂと、後壁４２の突起４０とを同一直線上に設けるようにした。これにより、Ｅ字型コア１３、１４とケース４とを樹脂モールドにより一体化する際、必要最低限の数や接触面積の突起４０でＥ字型コア１３、１４を支持することができる。そのため、Ｅ字型コア１３、１４とケース４とを接合する下カバー２Ｂを構成するための樹脂の流動性を向上させることができ、下コア１０Ｂとケース４との放熱経路を確保することができる。すなわち、突起４０を介してケース４とＥ字型コア１３、１４とが直接接触する場合でも放熱経路が形成されるが、Ｅ字型コア１３、１４と突起４０の接合面に微細な凹凸があると、空気層ができてしまい、熱抵抗が増大する場合がある。本実施形態によれば、突起４０の数や接触面積を小さくすることができるので、Ｅ字型コア１３、１４及びケース４に微細な凹凸があっても、樹脂が入り込み、熱抵抗を低減させることができる。 (3) The reactor of the present embodiment includes an upper unit 10A and a lower unit 10B, and is housed in a case 4, and the upper core 1A and the lower core 1B are joined to form an annular core. Further, the injection mark 30B and the protrusion 40 are provided on the same straight line. Here, the protrusion 40 of the front wall 42, the injection mark 30B, and the protrusion 40 of the rear wall 42 are provided on the same straight line with the present reactor viewed from the bottom. As a result, when the E-shaped cores 13 and 14 and the case 4 are integrated by a resin mold, the E-shaped cores 13 and 14 can be supported by the minimum number of protrusions 40 having a contact area. Therefore, the fluidity of the resin for forming the lower cover 2B for joining the E-shaped cores 13 and 14 and the case 4 can be improved, and the heat dissipation path between the lower core 10B and the case 4 can be secured. can. That is, even when the case 4 and the E-shaped cores 13 and 14 come into direct contact with each other via the protrusion 40, a heat dissipation path is formed, but fine irregularities are formed on the joint surface between the E-shaped core 13 and 14 and the protrusion 40. If there is, an air layer may be formed and the thermal resistance may increase. According to the present embodiment, the number of protrusions 40 and the contact area can be reduced, so that even if the E-shaped cores 13, 14 and the case 4 have fine irregularities, the resin enters and the thermal resistance is reduced. be able to.

（４）突起４０は、Ｅ字型コア１３、１４の直交面に沿って間隔を空けて２以上設けるようにした。これにより、モールド成形法によるコアとケース４との一体化の際に、樹脂の射出圧を安定的に受けることができるので、コアとケース４との位置決めの正確性が向上し、生産性を向上させることができる。 (4) Two or more protrusions 40 are provided at intervals along the orthogonal planes of the E-shaped cores 13 and 14. As a result, when the core and the case 4 are integrated by the molding method, the injection pressure of the resin can be stably received, so that the accuracy of positioning between the core and the case 4 is improved and the productivity is improved. Can be improved.

（５）下カバー２Ｂは、隙間１９の樹脂がケース４との接合部分と一続きで成るようにした。これにより、Ｅ字型コア１３、１４間に熱抵抗の大きい空気が介在することなく、コア１中央の熱を下カバー２Ｂを介してケース４に放熱することができるので、温度の下がりにくいリアクトル内部のコア１の温度を下げることができる。すなわち、隙間１９の樹脂によって、製造コストおよび製造工数が削減できるだけでなく、コア１内部からケース４までの放熱経路を形成することができる。 (5) In the lower cover 2B, the resin in the gap 19 is continuous with the joint portion with the case 4. As a result, the heat in the center of the core 1 can be dissipated to the case 4 via the lower cover 2B without intervening air having a large thermal resistance between the E-shaped cores 13 and 14, so that the reactor whose temperature does not easily drop can be dissipated. The temperature of the internal core 1 can be lowered. That is, the resin in the gap 19 not only reduces the manufacturing cost and the manufacturing man-hours, but also can form a heat dissipation path from the inside of the core 1 to the case 4.

（６）コア１の少なくとも一部に装着されたコイル５を備え、ケース４は、開口部４７が設けられた底板４１を有し、コイル５は、巻軸を開口部４７に向けてケース４に配置されるようにした。これにより、コア１からの漏れ磁束に対してシールド効果によるインダクタンス低下を抑制できる。 (6) The case 4 includes a coil 5 mounted on at least a part of the core 1, the case 4 has a bottom plate 41 provided with an opening 47, and the coil 5 has a winding shaft directed toward the opening 47. It was made to be placed in. As a result, it is possible to suppress a decrease in inductance due to the shielding effect against the leakage flux from the core 1.

（７）ケース４は、底板４１と一体に設けられた対向する前壁４２および後壁４３と、前壁４２および後壁４３を繋ぐとともに、開口部４８が設けられた側壁４４を有し、下カバー２Ｂは、開口部４８を塞ぐ左右の壁２４を有し、左右の壁２４が開口部４８の縁と接合されるようにした。これにより、コア１やコイル５の周囲に部分的にケース４がない部分があるので、ケース４にコア１からの漏れ磁束が貫くことによって、ケース４が発熱することがなく、リアクトル損失の低減が可能になる。また、金属製のケース４の壁が樹脂性の左右の壁２４に置き換わっているので、軽量化したリアクトルを得ることができる。 (7) The case 4 has a side wall 44 that connects the front wall 42 and the rear wall 43 that are integrally provided with the bottom plate 41, and the front wall 42 and the rear wall 43, and is provided with an opening 48. The lower cover 2B has left and right walls 24 that close the opening 48, so that the left and right walls 24 are joined to the edge of the opening 48. As a result, since there is a part around the core 1 and the coil 5 where the case 4 is not provided, the case 4 does not generate heat due to the leakage flux from the core 1 penetrating the case 4, and the reactor loss is reduced. Will be possible. Further, since the wall of the metal case 4 is replaced with the resin-based left and right walls 24, a lightweight reactor can be obtained.

［２．他の実施形態］
本発明は、第１の実施形態に限定されるものではなく、下記に示す他の実施形態も包含する。また、本発明は、第１の実施形態及び下記の他の実施形態を全て又はいずれかを組み合わせた形態も包含する。さらに、これらの実施形態を発明の範囲を逸脱しない範囲で、種々の省略や置き換え、変更を行うことができ、その変形も本発明に含まれる。 [2. Other embodiments]
The present invention is not limited to the first embodiment, but also includes other embodiments shown below. The present invention also includes a combination of the first embodiment and all or any of the following other embodiments. Further, various omissions, replacements, and changes can be made to these embodiments without departing from the scope of the invention, and modifications thereof are also included in the present invention.

（１）第１の実施形態では、コア部材は、Ｅ字型コア１１〜１４としたが、Ｕ字型コア、Ｉ字型コアなど直交面が他の形状のコアを用いても良い。また、コア部材を同じＥ字型コアを用いて、各コア部材のプレス方向の大きさを同じにしたが、異なるようにしても良い。 (1) In the first embodiment, the core member is an E-shaped core 11 to 14, but a core having another shape on the orthogonal plane such as a U-shaped core or an I-shaped core may be used. Further, although the same E-shaped core is used for the core members and the sizes of the core members in the pressing direction are the same, they may be different.

（２）第１の実施形態では、ゲート７３をＥ字型コア１３、１４の隙間１９に沿って、底面側となるヨーク１８側に設けたが、隙間１９に沿っていれば、外脚１６、１７の外側に設けても良い。この場合、注入痕３０Ｂは、左右の壁２４に設けられる。 (2) In the first embodiment, the gate 73 is provided along the gap 19 of the E-shaped cores 13 and 14 on the yoke 18 side which is the bottom side, but if it is along the gap 19, the outer leg 16 is provided. , 17 may be provided on the outside. In this case, the injection marks 30B are provided on the left and right walls 24.

（３）第１の実施形態では、上カバー２Ａの注入痕３０Ａを中脚１５の部分の中間位置に設けるようにしたが、外脚１６間、及び外脚１７間にそれぞれ設けるようにしても良い。この場合、注入痕３０Ａは、Ｅ字型コア１１、１２の隙間１９に沿って設けられる。また、直交面のうち中脚１５及びヨーク１８の部分を露出させる一対の開口部２１に代えて、各注入痕３０Ａを介在させて対向し、直交面のうち外脚１６及びヨーク１８の部分を露出させる一対の開口部、並びに、直交面のうち外脚１７及びヨーク１８の部分を露出させる一対の開口部が設けられる。 (3) In the first embodiment, the injection mark 30A of the upper cover 2A is provided at the intermediate position of the middle leg 15, but it may be provided between the outer legs 16 and the outer legs 17, respectively. good. In this case, the injection mark 30A is provided along the gap 19 of the E-shaped cores 11 and 12. Further, instead of the pair of openings 21 that expose the parts of the middle leg 15 and the yoke 18 in the orthogonal plane, each injection mark 30A is interposed and opposed to each other, and the parts of the outer leg 16 and the yoke 18 in the orthogonal plane are opposed to each other. A pair of openings to be exposed and a pair of openings to expose the outer legs 17 and the yoke 18 of the orthogonal planes are provided.

１コア
１Ａ上コア
１Ｂ下コア
１０Ａ上ユニット
１０Ｂ下ユニット
１１〜１４Ｅ字型コア
１５中脚
１６、１７外脚
１８ヨーク
１９隙間
２樹脂部材
２Ａ上カバー
２Ｂ下カバー
２１開口部
２３被覆部
２４左右の壁
２５張出部
３０Ａ、３０Ｂ注入痕
４ケース
４０突起
４１底板
４２前壁
４３後壁
４４側壁
４５凹部
４６段部
４６ａネジ穴
４７、４８開口部
５コイル
６充填成形部
７１下型
７２上型
７３ゲート
８１下型
８２上型
８３ゲート
９１ネジ 1 Core 1A Upper core 1B Lower core 10A Upper unit 10B Lower unit 11-14 E-shaped core 15 Middle legs 16, 17 Outer legs 18 York 19 Gap 2 Resin member 2A Upper cover 2B Lower cover 21 Opening 23 Cover 24 Left and right Wall 25 Overhanging part 30A, 30B Injection mark 4 Case 40 Protrusion 41 Bottom plate 42 Front wall 43 Rear wall 44 Side wall 45 Recessed part 46 Step part 46a Screw hole 47, 48 Opening part 5 Coil 6 Filling molding part 71 Lower mold 72 Upper mold 73 Gate 81 Lower type 82 Upper type 83 Gate 91 Screw

Claims

A first core in which a plurality of core members are arranged with a gap along the pressing direction, and
A first resin body that covers at least a part of the periphery of the plurality of core members and fixes the plurality of core members to form the first core.
Equipped with
In the gap, the resin constituting the first resin body adheres to the plurality of core members and intervenes.
The first resin body has
In the gap portion, the injection mark of the resin and
A pair of first openings that face each other with the injection marks interposed therebetween and expose an orthogonal plane orthogonal to the press direction of the core member.
Is provided,
A core unit featuring.

The injection mark and the pair of first openings are provided on the same straight line.
The core unit according to claim 1.

A second core in which a plurality of core members are arranged with a gap along the pressing direction, and
A case for accommodating the second core and
A second resin body that covers at least a part of the periphery of the plurality of core members, fixes the plurality of core members to form the second core, and is joined to the case.
Equipped with
In the gap, the resin constituting the second resin body is in close contact with the plurality of core members and intervenes.
The case has a bottom plate, facing front and rear walls integrally provided with the bottom plate, a side wall connecting the front wall and the rear wall, and having a second opening.
The second resin body has left and right walls that close the second opening.
The left and right walls are joined to the edge of the second opening.
A core unit featuring.

A second core in which a plurality of core members are arranged with a gap along the pressing direction, and
A case for accommodating the second core and
A second resin body that covers at least a part of the periphery of the plurality of core members, fixes the plurality of core members to form the second core, and is joined to the case.
Equipped with
In the gap, the resin constituting the second resin body is in close contact with the plurality of core members and intervenes.
The second resin body is provided with injection marks of the resin constituting the second resin body in the gap portion.
The case faces the case with the injection mark interposed therebetween, and the inner wall facing the orthogonal surface of the core member orthogonal to the pressing direction is provided with a protrusion protruding toward the orthogonal surface.
A core unit featuring.

The injection mark and the protrusion of the second resin body are provided on the same straight line.
4. The core unit according to claim 4.

Two or more of the protrusions are provided at intervals along the orthogonal plane of the core member in the second core.
The core unit according to any one of claims 4 or 5.

In the second resin body, the resin in the gap is continuous with the joint portion with the case.
The core unit according to any one of claims 3 to 6.

The bottom plate is provided with a third opening.
The second resin body closes the third opening and is joined to the edge of the third opening, and an injection mark is provided in the portion that closes the third opening.
The core unit according to claim 3.

The case has a bottom plate, facing front and rear walls integrally provided with the bottom plate, a side wall connecting the front wall and the rear wall, and having a second opening.
The second resin body has left and right walls that close the second opening.
The left and right walls are joined to the edge of the second opening and
The bottom plate is provided with a third opening.
The second resin body closes the third opening and is joined to the edge of the third opening, and the injection mark is provided in the portion that closes the third opening.
4. The core unit according to claim 4.

The core member is an E-shaped core whose orthogonal plane orthogonal to the pressing direction forms an E-shape.
The core unit according to any one of claims 1 to 9.

The core member is a dust core.
The core unit according to any one of claims 1 to 10.

The core unit according to claim 1 or 2, and
With the core unit according to claim 8 or 9.
Equipped with
The core unit according to claim 1 or 2 is housed in the case.
The first core and the second core are joined to form an annular core.
Reactor featuring.

A coil mounted on at least a portion of the annular core
The coil is arranged in the case with the winding shaft facing the third opening.
12. The reactor according to claim 12.